Modular building construction

ABSTRACT

A modular system of construction of loft apartment buildings. This type of unit is in high demand in many metropolitan areas, and the modular nature of the inventive buildings allows them to be produced quickly and at low cost. In addition, the invention provides a novel system for interconnecting apartments quickly during construction, providing further cost savings. A mix of apartment types, including handicapped-accessible apartments, may be placed in each building, with the proportions of different apartment types being tailored to the needs of the local market and the constraints of local building codes. The apartment modules may be sized to permit convenient shipping of modules within the constraints of overland shipping regulations.

This application is a continuation-in-part of U.S. application Ser. No.09/252,635, filed Feb. 19, 1999 and issued Dec. 7, 2004 as U.S. Pat. No.6,826,879, which is incorporated herein by reference.

FIELD OR THE INVENTION

The present application relates to modular systems and methods forassembling multiunit buildings from multiple vertically stacked modules,and particularly to systems and methods in which units may be connectedby preformed vertical chases.

BACKGROUND OF THE INVENTION

Increasing demand for affordable housing in major metropolitan areas hasnecessitated the development of creative systems for housing design. Onesuch solution is the renovation of underutilized or functionallyobsolete buildings, often former industrial sites, into housing units.One advantage of such units has been the ability to produce “loft”apartments, in which at least a portion of each unit has double-heightceilings. These apartments have become popular in many markets, to thepoint that demand for such units may exceed the available supply ofbuildings to retrofit. The present invention provides a solution to thisshortage, by providing an affordable system for building such units fromthe ground up.

In addition to the limited supply of buildings suited to be converted toloft apartments, another major impediment to the construction ofmultiunit housing has been the need to provide adequate parking spacefor each unit. The present invention also provides a solution whichallows inexpensive modular construction of living units over anassociated parking area, so that a larger number of apartments may beplaced in a given lot while conforming to local zoning codes andproviding adequate parking facilities.

SUMMARY OF THE INVENTION

The present invention provides a modular system of construction of loftapartment buildings. This type of unit is in high demand in manymetropolitan areas, and the modular nature of the inventive buildingsallows them to be produced quickly and at low cost. In addition, theinvention provides a novel system for interconnecting apartments quicklyduring construction, providing further cost savings. A mix of apartmenttypes, including handicap-accessible apartments, may be placed in eachbuilding, with the proportions of different apartment types beingtailored to the needs of the local market and the constraints of localbuilding codes. The apartment modules may be sized to permit convenientshipping of modules within the constraints of overland shippingregulations.

In one aspect, the invention comprises a multiunit building of modularconstruction, wherein multiple units of the building are each formedfrom two prefabricated modules, a lower module comprising a floor andfour wall sections, and an upper module comprising a ceiling and fourwall sections. At least one room of the unit extends the full height ofthe unit, i.e., from the floor of the lower module to the ceiling of theupper module, and a vertical utility chase extends from the floor of thelower module to the ceiling of the upper module. The unit may have amezzanine level, in which at least one room is substantially containedwithin the upper module. The units may be arranged horizontally,vertically, or both. The building may also comprise lobby units, whichmay be vertically stacked and connected by a staircase and/or anelevator. The modules may be sized to comply with overland shippingregulations for transportation on a flatbed truck.

In another aspect, the invention comprises a method of buildingconstruction, comprising installing a foundation, placing a lowerbuilding module above the foundation, placing an upper building moduleon the lower module and securing the modules together. The modulescombine to form a building unit, in which at least one room spans thedistance from the floor of the first module to the ceiling of the secondmodule, and a vertical utility chase extends from the floor of the lowermodule to the ceiling of the upper module. Multiple units may be placedvertically, horizontally, or both. Horizontally adjacent units may beconnected by a utility feed. The modules may be constructed remotely andtransported to the building site.

In still another aspect, the invention comprises a multiunit modularbuilding, wherein horizontally adjacent units are connected via acorridor and a horizontal utility chase containing a utility feed, andthe units also comprise a vertical utility chase. The utility feed mayinclude water pipes, mechanical piping, electrical wiring,communications and security systems, and life safety systems. Thebuilding may further comprise a lobby unit connected to the buildingunits. Both building units and lobby units may be vertically stacked,and stacked lobby units may be connected via a vertical utility chase.

In yet another aspect, the invention comprises a method of constructinga modular building comprising installing two units, each containing acorridor section and a horizontal utility chase section containing autility feed, and connecting the units and the utility feeds. The unitsalso comprise a vertical utility chase. The utility feeds may includewater pipes, mechanical piping, electrical wiring, communications andsecurity systems, and life safety systems. The units may each comprisetwo vertically stacked modules as described above, and such verticallystacked units may combine to form a continuous vertical utility chase.The building may further contain one or more lobby units which may beconnected to the utility feeds, and which may be stacked. Stacked lobbyunits may be connected via a vertical utility chase.

BRIEF DESCRIPTION OF THE DRAWING

The invention is described with reference to the several figures of thedrawing, in which,

FIG. 1 is a cutaway view of an assembled apartment building comprisingfour apartment types according to the invention;

FIG. 2 is an exploded view of a “base” apartment of the building of FIG.1, showing how two modules are stacked to form the apartment;

FIG. 3 is a cutaway view of the apartment unit of FIG. 2;

FIG. 4 is a perspective view of two units as shown in FIG. 2,illustrating corridor access and utility chase connections;

FIG. 5 is an exploded view of an “intermediate” apartment of thebuilding of FIG. 1;

FIG. 6 is a perspective view of two units as shown in FIG. 5,illustrating corridor access and utility chase connections;

FIGS. 7 a-7 f are perspective and cutaway views of each unit as placedin an assembled building;

FIG. 8 shows a lobby unit for use with the units pictured in FIG. 5; and

FIG. 9 shows a multiunit building in which individual units compriseboth horizontal and vertical chases.

DETAILED DESCRIPTION

The invention is described below with reference to certain preferredembodiments, in which an assembled apartment building comprises threetypes of living units, placed upon a conventional (nonmodular)semi-depressed parking level. It will be understood by those skilled inthe art that this represents only one embodiment of the invention, andthe invention encompasses many modifications and variations of thestructures described herein. For example, the number, size, and shape ofthe living units may be varied over a wide range, and may includeapartments, assisted living units, hotel rooms or suites, extended stayunits, dormitory rooms or suites, or other types living units. Theapartment units need not all be loft units; in fact, it may be desirableto include some single-level units in order to comply withhandicap-access regulations. The outer walls of each unit need not becoplanar as shown below; the invention also contemplates staggered oroffset arrangements of units. Further, the principles of the inventionmay be applied to the construction of multiunit office or industrialbuildings, as well as living units. Commercial and dwelling units mayeven be mixed in a single building, within the constraints of localbuilding codes.

An apartment building according to the invention is illustrated incutaway view in FIG. 1, generally as 10. The building 10 comprises threetypes of living units: base units 12, two stories of intermediate units14, and top units 16. The illustrated building 10 also comprises asemidepressed parking level 18. The size and shape of units 12, 14, and16 may be more clearly seen in FIG. 7 a-7 f.

An exploded view of a base unit 12 is shown in FIG. 2. The unitcomprises a lower module 20 and an upper module 22. Lower module 20comprises a floor 24 and four vertical outer walls 26. Upper module 22comprises a ceiling 28, four vertical outer walls 30, and a floorsection 32. Floor section 32 spans only a portion of the module. Thus,when the modules are stacked to form the apartment unit, the unitcomprises a great room 34 which has a floor-to-ceiling height spanningthe two modules. Large windows 36 are preferably provided for the greatroom 34 to further increase the spacious feeling of the room afforded bythe high ceiling. The rear section 38 of the apartment comprisesfloor-level rooms having section 24 as their floor, and mezzanine roomshaving section 32 as their floor. Internal stairs 40 (more clearly seenin FIG. 3, a cutaway view of the same unit) allow access to themezzanine level from the floor level.

It is preferable that modules 20 and 22 conform to overland shippingregulations for easy transportation. For example, a module may have awidth not exceeding 14 feet, a length not exceeding 66 feet, and aheight not exceeding 11 feet. These sizes are exemplary, and may beadjusted depending on the method of shipping used and on local shippingregulations. For example, greater size flexibility may be afforded whenit is practical to ship the units by barge, ship, or helicopter, or whenthe modules are constructed at a location near the building site.

Access to the unit 12 is afforded by a corridor 42 which opens onto themezzanine level. It will be seen that when multiple units 12 are placedside-by-side to form a building level, the corridors 42 will connect toform a joint accessway to the individual apartment units. A pair ofunits with connected corridor sections 42 can be seen in FIG. 4.

Shown adjacent to the corridor 42 is a horizontal chase 44 wherebybuilding services such as water pipes, electrical wiring, communicationsand security systems, and sprinkler and other life safety systems (notshown) may be provided. It is an advantage of this type of buildingmodule that access to water pipes and the like may be provided by anaccess panel (not shown) on the common corridor 42, removing thenecessity for workmen to enter individual apartments when performingmaintenance.

It is a further advantage of the horizontal chase 44 that it facilitateseasy connection of building services such as water and electricity.Pipes and wiring may be preinstalled in the chase when the unit isconstructed, so that they need only be “plugged in” to an adjacent unit12 when the building is assembled on-site. The prior art almostexclusively uses vertical chases for these services, so that pipes andwires must be fed through the chase by hand after the building isassembled.

The ease of connection of the building services also facilitates on-site“finishing” of the apartment unit. In this concept of buildingconstruction, module 22 is stacked atop module 20, and chase utilityfeed connections to the previously installed adjacent unit areimmediately made. The newly installed unit 12 is then immediatelypowered, and workmen can simply turn on the preinstalled lights and plugpower tools into existing wall outlets in order to finish securing themodules together and to the adjacent unit, and to install cosmeticelements such as molding to cover the module joints. In addition,construction site security can be maintained by immediate connectivityto a central security monitor specifically equipped for temporary dutyon the active construction sites. Sprinkler systems can be activated farin advance of conventional construction methods, reducing the risk ofdamage by fire.

A second type of unit 14 is illustrated in FIG. 5. The modules 46 and 48making up the unit 14 are of approximately the same size and shape asmodules 20 and 22, but they combine to form different apartment shapes.The apartments does not stretch across the full width of the building 10as does unit 12; instead, each apartment is approximately one-half thelength and twice the width of unit 12, and separate apartments areplaced on opposite sides of the corridor 50. The units on either side ofthe corridor need not be identical in space or layout, if it is desiredto have a building with a variety of apartment configurations. In orderto provide utility feeds for apartments on either side of the corridor50 in this configuration, it is preferable to place the horizontalutility chase 52 under (as shown) or over the corridor 50. Access panelsmay be placed in the floor (or ceiling) corridor 50 if desired, but itwill generally be found preferable to access the utility chase 52 frominside the apartment units in this configuration. FIG. 6 is aperspective view of two assembled units 14, with corridor 50 and utilitychase 52 connections extended for clarity.

A third type of unit 16 for placement on the top level of the building10 is shown in FIGS. 7 e and 7 f. As pictured, this unit comprises threemodules and is three times the width of unit 12. It will be apparent tothose skilled in the art that other unit shapes and sizes may also beused. As shown, unit 12 is a single-level unit (which may be madehandicap-accessible if desired), but the top unit may also have amezzanine if preferred. The modules making up this unit preferablycomprise integral membrane roofing and roof drains, and may furthercomprise skylights, coffered ceilings, clerestories or the like toenhance the perception of light and space in the units. Unit 16comprises horizontal chases, as do the other units 12 and 14, for rapidconnection of adjacent units.

Buildings according to the invention are extremely economical in spaceusage. For example, in a preferred embodiment, the height X of units 12and 14 may be 18 feet. The height Y of units 16 may be 10.5 feet, andthe elevation of ground floor units 12 above the grade Z may be 5.5feet, for a total building height of 70 feet. This configuration fallswithin the Building Officials and Code Administrators (BOCA)International standard for Type 3A construction of a multi-family, fullysprinklered building. (Because mezzanine areas are limited to _the areabelow them under the BOCA definitions, the pictured unit is considered afour-story building, and falls within the five story limit for abuilding of this type. Because the standard allows a five story buildingof this height, it may be desirable for the upper levels in one floor ofapartments to be expanded, offering greater flexibility in apartmentdesign).

At least one vertical chase 54 is provided for the building in order toconnect the daisy-chained horizontal chases of each level of thebuilding to a central utility feed. This vertical chase may run parallelto an elevator shaft 56, for example, in order to provide further spacesavings. FIG. 8 shows a modular unit for a lobby area, from which tworows of units 14 may extend. (While the pictured unit is configured forconnection with unit type 14, it will be apparent to those skilled inthe art that lobby units for connections to unit types 12 and 16 caneasily be constructed). Apertures 58 are provided for connection withthe corridor 50, and apertures 60 are provided for connection with thehorizontal chase 52. The lobby further comprises emergency stairs 62.

Vertical chases may also be provided for the individual units. When suchchases are combined with the horizontal chases described above, a“network” of utility feeds can be created. Such a network may be usefulwhen a communications network is to be installed in the building, orwhen it is desired to bring certain services up from a central system inthe basement or roof, while other service feeds come from systems in thelobbies or elsewhere. For example, water pipes and HVAC ducts might runvertically from the basement and roof, respectively, while electricalwires run horizontally from vertical trunk cables. Alternatively, allservices may be provided via the vertical chases, which may still beconfigured to allow corridor access.

A configuration showing both vertical and horizontal chases within theliving units is shown in FIG. 9. As shown, each unit comprises a sectionof a horizontal chase 44 and a vertical chase 64. These chases adjoin atjunction 66, forming a three-dimensional “network” of utility feeds. Asshown, the vertical chases 64 adjoin corridor 42, so that they may beaccessed by service personnel from outside the living unit.

The length of base units 12 is preferably somewhat longer than that ofthe upper modules. This additional length ensures an interior widthinside the foundation walls suitable for ease of parking andmaneuvering, and serves as a basis for articulating the architecturalbase of a building constructed according to the invention. The extralength further serves continuous, uninterrupted bearing walls for theunits above.

All units 12, 14, 16 are preferably constructed with “hard-shellintegrity,” allowing improved fire safety and sound deadening (high STCfor residential construction). The integral roof construction of the topunits 16 means that any roof failure is localized and the possibility ofcollateral or residual damage is minimized.

The buildings of the invention can be constructed extremely rapidly. Anexemplary 96-unit building in the configuration shown in FIG. 1, forexample, may be constructed in a period of about 16 weeks. Preferably,construction begins with laying of the building foundation andconstruction of the semidepressed parking structure, if included. Acolumn of level lobbies, containing the elevator shaft and verticalutility feed is then constructed, and building units can then be placedin one or more wings extending from the lobby area. It will generally befound preferable to add modules to the building in stacks, placing alllevels over a given base unit 12 before placing the next base unit, butconstruction may also proceed by placing all ground level units,followed by all second level units, etc.

It will generally be preferable for modules to be finished as much aspossible in the factory, before shipping to the building site. This isfacilitated by the horizontal chase structure which allows utility feedsto be placed in the chase during manufacturing, so that only splicesbetween units need be completed in the field. The attachment of thelower module 20 to the upper module 22 must be accomplished in thefield, but much of the initial machining (e.g., drilling holes,providing quick-connect fittings for ductwork and plumbing) may beaccomplished at the factory, and all necessary hardware may be placed inone of the modules during the manufacturing process, allowing quick andeasy connection of the modules. Carpeting, windows, etc. may all bepreinstalled at the factory, allowing improved working conditions forinstallation personnel and lower costs for the manufacturer.

Other embodiments of the invention will be apparent to those skilled inthe art from a consideration of the specification or practice of theinvention disclosed herein. It is intended that the specification andexamples be considered as exemplary only, with the true scope and spiritof the invention being indicated by the following claims.

1. A multiunit building, comprising: multiple connected units, each unitbeing formed by two prefabricated modules, a first module comprising afloor and four wall sections, and a second module comprising a ceilingand four wall sections, wherein the second module is stacked verticallyatop the first module and connected thereto; a room of the unit soformed extends from the floor section of the first module to the ceilingsection of the second module; and a vertical utility chase runs from thefloor of the first module to the ceiling of the second module.
 2. Thebuilding of claim 1, wherein at least two units are stacked one atopanother, and wherein the vertical utility chase is continuous betweenthe at least two units.
 3. The building of claim 1, wherein at least twounits are placed horizontally adjacent to one another.
 4. The buildingof claim 1, further comprising multiple lobby units connected to themultiple connected units.
 5. The building of claim 4, wherein themultiple lobby units are vertically stacked and connected by at leastone staircase.
 6. The building of claim 1, wherein the unit comprises aroom substantially contained within the second module.
 7. The buildingof claim 1, wherein the modules are sized to be transported on a flatbedtruck.
 8. A method of building construction, comprising: constructing afoundation; placing a first module comprising a floor and four wallsections above the foundation; placing a second module comprising aceiling and four wall sections atop the first module; and securing thesecond module to the first module to form a building unit, wherein aroom of the unit so formed extends from the floor section of the firstmodule to the ceiling section of the second module; and a verticalutility chase extends from the floor of the first module to the ceilingof the second module.
 9. The method of claim 8, further comprisingvertically stacking multiple building units, each unit so stackedcomprising a first module having a floor and four wall sections and asecond module having a ceiling and four wall sections, wherein thevertical utility chase is continuous between the stacked units andfurther comprising connecting a utility feed within the vertical utilitychase.
 10. The method of claim 8, further comprising connecting a secondunit horizontally adjacent to the first unit, the second unit comprisinga first module having a floor and four wall sections and a second modulehaving a ceiling and four wall sections.
 11. The method of claim 10,wherein the first unit and the second unit each comprise a horizontalchase containing at least one utility feed, and further comprisingconnecting the utility feed of the first unit to the utility feed of thesecond unit.
 12. The method of claim 8, wherein the first module and thesecond module are constructed in a remote location and transported tothe site of the foundation for placement thereon.
 13. A multiunitmodular building, comprising: multiple connected units, each unitcomprising a module having a corridor section, a module comprising ahorizontal utility chase section, and a module comprising a verticalutility chase section, wherein the corridor sections connect to form anaccess corridor, the horizontal utility chase sections connect to form ahorizontal utility chase containing a first utility feed, and thevertical chase sections connect to form a vertical utility chasecontaining a second utility feed.
 14. The building of claim 13, whereinat least two units are stacked one atop another.
 15. The building ofclaim 13, wherein at least two units are placed horizontally adjacent toone another.
 16. The building of claim 13, further comprising multiplelobby units connected to the multiple connected units.
 17. The buildingof claim 16, wherein the multiple lobby units are vertically stacked andconnected by at least one staircase.
 18. The building of claim 17,wherein the vertically stacked lobby units are connected by at least onevertical chase containing a utility feed.
 19. The building of claim 13,wherein the utility feed is selected from the group consisting of waterpipes, mechanical piping, electrical wiring, communications and securitysystems, and life safety systems.
 20. The building of claim 13, whereinthe modules are sized to be transported on a flatbed truck.
 21. Thebuilding of claim 13, wherein the corridor section and the horizontalutility chase section are both contained within the same module.
 22. Amethod of constructing a modular building, comprising: installing afirst unit comprising a first corridor section, a first horizontalutility chase section, and a first vertical utility chase section,wherein the first horizontal utility chase section and the firstvertical utility chase section each contain a utility feed; installing asecond unit comprising a second corridor section, a second horizontalutility chase section, and a second vertical utility chase section,wherein the second horizontal utility chase section and the secondvertical utility chase section each contain a utility feed; connectingthe units so that the first corridor section and the second corridorsection combine to form an access corridor, and the first horizontalutility chase and the second horizontal utility chase combine to form acontinuous utility chase; and connecting the horizontal utility feed ofthe first unit and the horizontal utility feed of the second unit forsupply of utility services to the units.
 23. The method of claim 22,wherein the utility feeds are selected from the group consisting ofwater pipes, mechanical piping, electrical wiring, communication andsecurity systems, and life safety systems
 24. The method of claim 22,wherein each unit comprises two vertically stacked modules.
 25. Themethod of claim 22, wherein the first unit and the second unit areconstructed in a remote location and transported to the site of thebuilding.
 26. The method of claim 22, further comprising installing afirst lobby unit comprising a utility chase section containing a lobbyutility feed and connecting the lobby utility feed to the horizontalutility feed of the first unit.
 27. The method of claim 26, furthercomprising installing a second lobby unit comprising a utility chasesection containing a lobby utility feed atop the first lobby unit andconnecting the lobby utility feeds of the first and second lobby unitsvia a vertical utility chase.
 28. The method of claim 22, furthercomprising installing a third unit comprising a third corridor section,a third horizontal utility chase section, and a third vertical utilitychase section, wherein the third horizontal utility chase section andthe third vertical utility chase section each contain a utility feed;connecting the third unit to the first unit so that the first verticalchase section and the third vertical chase section combine to form acontinuous vertical utility chase; and connecting the vertical utilityfeed of the first unit and the vertical utility feed of the third unitfor supply of utility services to the units.
 29. A multiunit modularbuilding, comprising: multiple connected units, each unit comprising amodule having a corridor section and a module comprising a verticalutility chase section, wherein the corridor sections connect to form anaccess corridor, and the vertical chase sections connect to form avertical utility chase containing a utility feed.
 30. A method ofconstructing a modular building, comprising: installing a first unitcomprising a first corridor section and a first vertical utility chasesection, wherein the first vertical utility chase section contains afirst utility feed; installing a second unit comprising a secondcorridor section and a second vertical utility chase section, whereinthe second vertical utility chase section contains a second utilityfeed; installing a third unit comprising a third corridor section and athird vertical utility chase section, wherein the third vertical utilitychase section each contains a third utility feed; connecting the firstand second units so that the first corridor section and the secondcorridor section combine to form an access corridor; connecting thefirst and third unit sso that the first vertical chase section and thethird vertical chase section combine to form a continuous verticalutility chase; and connecting the vertical utility feed of the firstunit and the vertical utility feed of the third unit for supply ofutility services to the units.